Manufacture of surface coverings



Dec. 4, 1934. Q MCCARTHY 1,983,180

MANUFACTURE (5F SURFACE COVEFINGS Filed Nov. 21. 1930 2 Sheets-Sheet lDec. 4, 1934. J Q MCCARTHY 1,983,180

MANUFACTURE OF SURF'AC E C OVER I NGS Filed Nov. 21, 1950 2 Sheets-Sheet2 'INVENTOR Patented Dec. 4, 1934 7 1,983,180 MANUFACTURE OF summoncovsamcs J. Clarence McCarthy,

Lancaster, Pa., assignor Armstrong Cork Company, Lancaster, Pa.,

a corporation of Pennsylvania Application November 21, 1930, Serial No.497,313

23 Claims.

. This invention relates to the manufacture of surface coverings, forexample, floor coverings having a paint surface and usually'referred toas-printed goods. The present invention, however, has to do with theapplication of the color, which may be oil paint,'-in such away as toblend the colors, and without the monotony of the repetition of patternwhich is characteristic of the usual printed goods. It is particularlyconcerned "'10 with the production of a surface having an appearancewhich simulates marble or other surfaces of varying tone and color andof irregular design. I v

In the manufacture of inlaid linoleum, marbles '15 are produced bycalendering diflerent colors of linoleum composition together andcarefully controlling the calender-ing conditions. Printed goods,however, have been signally faulty wherever it has been attempted tosimulate marbles or the like. A printing process is essentially onewherein the pattern is repeated, and when dealingwith the typeof paintemployed in the floor covering industry, or, for that matter, inemploying thetype of colors generally used in sur- '26 face coverings,the final result has been harsh and-mechanical in appearance, and haslacked the softness and fine blending of color characteristic of naturalmarbles.-

By my invention it is'possible at a low cost 180 to obtain a productwhich has the highly desirable qualities from the standpoint ofappearance of natural marbles without any apparent repetitions ofpattern and with'a soft blending of color not heretofore obtainable inpainted goods.

"86 I apply a color or colors to a backing, spread the samelongitudinally and laterally of the goods, and then engage the colorsthus spread and further spread them. Preferably the first spreadingaction is such as to form sinuous streaks of color which are thereafterspread. laterally and longitudinally. A doctor. blade serves admirablyfor spreading the color. Inpractice- Ihave applied color in spotsor-blobs on a painted backing, have spread the same into sinuous streaksof color by means" of a doctor blade, and have then engaged the streakswithv a second doctor blade for the purpose of furtherspreading andblending the same. The doctor blades are reciprocated as the materialmoves .thereunder, and the reciprocation may be effected by handv ormechanically. Preferably the blades are reciprocated in anirregularfashion and this may be done by acam.- Provision is further made foradjusting the angularity of the'blades to the path of travel of thematerial. -An adjustment of the angularity of a blade has a markedeffect on the appearance of the goods.

The color may be applied by means of paint guns of the usual character,such guns being electrically controlled and the paint being fed'under 0low air pressure so that the guns control the flow of paint and cause itto spatter to form spots or blobs of color on the goods as the samemoves thereunder.

In the accompanying drawings illustrating a present preferred embodimentof the invention,

Figure 1 is a diagrammatic view illustrating successive steps in themanufacture of a floor covering according to my invention;

Figure 2 is a view to full size of a piece of material in process ofmanuacture and showing the manner of applying the paint;

Figure 3 is a plan view more or less diagrammatic, illustrating themanner of applying and spreading the color; and

Figure 4 is a side elevation thereof.

The material illustrated in Figures 1 and 2 comprise a base material 2,such as the felt base ordinarily employed in the floor coveringindustry, having a uniform paint coating 3 thereon. This 30 coating maybe applied in any desired fashion, as by a coating blade or a roll. Ifit is of a quickdrying character, a solvent which will prevent itsdrying until after the marble en'ect has been obtained may be includedin the coating Prefer- B5 ably, however, an oil paint is used. In anyevent, it has proven to be the best practise to apply the spatteredcolor spots immediately after the coating operation. Thus, asillustrated in Fig. 2 of the drawings, the several colors which havebeen selected to make up the marble, are applied to the wet or tackybacking in spots or blobs 4. I have illustrated in Figure 1 theapproximate amount of color which is required on the backing to form amarble and have shown spots to full size in Figure 2. It will beunderstood that different colors are employed in this particularmaterial as is indicated by the different hatchings oi the drawings.

The spots of color are first spread into sinuous streaks, as indicatedby the portion M of Figure 1. As hereinafter described this is best doneby a reciprocating doctor blade. In Figure 1 the path of movement of thematerial is indicated by an arrow B, and the line of reciprocation ofthe doctor blade is indicated by the line DD,- and the blade is movedback and forth in varying amounts so as to give the sinuous streaking onthe portion M of the drawings. By this operation there is some blendingof the spots of color into the. coating 3, which is still wet or tacky.Moreover. the spots of color are spread out and the diil'erent colorsare blended somewhat, although they retain their individual character tosome extent. For example, if a spot of green paint is followed at somedistance by a spot of brown paint, there will be a sinuous streak ofgreen which will fade out into the background or fade into the browncolor, depending upon the spacing of the spots, and then there will be asinuous streak of the brown color, both of the streaks varying in widthand intensity of color from point to point. When spots of color liealongside one another orare closely spaced. they blend somewhat as thecolor is distributed :ide wise by the doctor blade, but the severalcolors and the streaks attributable to different spots are readilydistinguished when the material is in the condition indicated by thesection M of Figure 1.

The sinuous streaks are subsequently further blended, thus giving anappearance represented by the section N of Figure 1. As above stated andas hereinafter more fully described, this is preferably accomplished byanother reciprocating doctor blade. The second blade effectually removesany sharpness or harshness which may remain from the action of the firstdoctor blade and further blends and spreads the colors so as to destroypractically every vestige of mechanical action. Moreover, the mobilityor plasticity of the coating 3 is of material assistance in blending thewhole color scheme so as to obtain the desired appearance of marble.Thus the streaks and tinges of color are worked into the coating 3 in avery natural appearing manner. In the case of a lacquer, there is atendency for the lacquer to become tacky; and a very desirable marbleeffect is produced, the tackiness causing the material to be pulled outwhen it passes under the doctor blades, producing a very characteristicmarble. The second doctor blade may be actuated at a different anglefrom the first, or at a different rate or amplitude. By varying theseseveral factors the first formed sinuous streaks are so modified andobliterated that the resulting material has an appearance characteristicof natural marbles and entirely free from any mechanical appearance.

If desired, the material may be overprinted. I have illustrated this insection P of Figure 1, where black squares have been printed over thematerial so as to produce a pattern consisting of alternate black tilesand marble tiles.

Figures 3 and 4 illustrate an apparatus which maybe employed. Thematerial is advanced in any convenient manner, as by pin bands 10, thematerial being carried over the base or table indicated at 11. Thecoating 3 is applied to the material at the forward end of the machine(not shown), and the material is then passed beneath a series of paintguns 12 there being several rows of guns connected with paint tanks 13containing difierent colors. The guns are operated without sufilcientpressure to atomize the paint, and preferably under a pressure of from 5to 10 pounds. This pressure may be merely the head of pressure whichresults from placing the paint tanks 13 at an elevation above the guns.The

, operation of the guns may be more readily adjusted if pressure, as forinstance air pressure, is applied to the surface of the paint in thetanks 13. Where the color is such that but small spots or blobs aredesired, a relatively light pressure is desirable, and where the coloris a more predominating one, a relatively higher pressure is desirable.In any case, the paint is fed to the guns with sufiicient pressure tospatter rather than drip, this spattering taking place at predeterminedintervals. I have shown electromagnets 14 adapted to be energized bymeans of a control drum 15, whereby the supply of paint to the materialmay be controlled. The control drum 15 will be provided with a row ofcontact points 16 for each paint gun 12, and by varying thecircumferential length and the number and spacing of such contact pointsthe guns may be controlled as desired. For example, small spots ofcolor, such as illustrated at 4a. in Figure 2, may be applied, or longstreaks, such as illustrated at 41), may be obtained.

The doctor blade for forming the first series of sinuous streaks ofcolor is illustrated at 17 in Figure 3. It consists of a square metalbar18 having a thin flexible steel blade 19 secured thereto. This blade ispressed down on the material and its edge portion lies substantiallyflat thereover. The bar 18 has extensions 20 working in bearings 21. Thedoctor blade is reciprocated by hand or by any convenient mechanism. Ihave illustrated in Figure 3 a cam 22 bearing against a follower roller23 on-one of the extensions 20, the cam being carried on a shaft 24which is rotated by a drive mechanism, not shown. A spring 25 serves toreturn the doctor blade after each movement imparted to it by the cam.The shape of the cam may be varied so as to make the streaks irregular,as indicated in Figure l.

The doctor blade and its associated mechanism is mounted on a base plate26 which is pivoted at 2'7. The entire base plate may be swung aroundthe pivot 27 being held in position by bolts 28. In this manner thedirection of movement of the doctor blade relative to the path of travelof the material may be varied.

The final spreading of the color is effected by a second doctor bladeindicated at 30 in Figure 3. This doctor blade is shown as extending atright angles to the path of travel of the goods but it is mounted andcontrolled in the same manner as the doctor blade 17, so that itsinclination to the path of travel and its amplitude may be varied atwill.

Preferably the cams for actuating the doctor blades will be driven byelectric motors having a speed control, whereby the number ofreciprocations per unit of time may be varied as desired.

It will be seen that with these adjustments, coupled with the use ofcams of different shapes, an infinite variety of effects may beobtained. Even with a fixed setting there is no discernible repeat inthe pattern because the action of the paint guns is to some degreehaphazard and the colors are so spread and blended that it is'impossible for the eye to find any repeat in the goods.

I have illustrated and described a present preferred embodiment of theinvention. It will be understood, however, that the invention is notthus limited but may be otherwise embodied or practiced within the scopeof the following claims.

I claim:

1. In the manufacture of surface coverings, the steps consisting inapplying color to a backing, passing the same under a doctor blade whileeffecting relative lateral movement between the material and the doctorblade, thereby spreading the color, and then passing the material undera second doctor blade and eifecting relative lateral movement wherebythe color is further spread.

2. In the manufacture of surface coverings, the steps consisting inapplying color to a backing, passing the same under a doctor blade andeffectmam-so ing relative lateral movement of the doctor blade andthe'material so as to spread the 6010:- into sinuous streaks, passingthe same under a second doctor blade and effecting relative lateralmovement'so as to further spread the colon-and varying the angularityof'at least'o'ne doctor blade relative to the path of movement'ofthe-materi l '1 1 3. In the manufacture of surface coverings, the

steps consisting 'inapplyin'g color to a backing? passing the'same undera doctor blade and effect-j ing relative lateral movement of the doctorblade and the material so as to spread-thecolor i'ntd sinuous streaks,passing the same under a second doctor blade and effecting relativelateral movement so as to further spread the color, and varying theamplitude of said relative lateral movement for at least one of thedoctor blades.

4. In the manufacture of surface coverings, the steps consisting inapplying color to a backing, passing the same under a doctor blade andeffecting relative lateral movement of the doctor blade and the materialso as to spread the color into sinuous streaks, passing the same under asecond doctor blade and effecting relative lateral movement so as tofurther spread the color, said relative movement of the doctor bladesand the material being in a reciprocable manner, and varying the numberof reciprocations of at least one of the doctor blades in a unit oftime.

5. In the manufacture of surface coverings, the steps consisting incoating a backing, applying color to the coating before the latter ishard or firm, passing the same under a doctor blade while effectingrelative lateral movement between the material and the doctor blade,thereby spreading the color, and then passing the material under asecond doctor blade and eifective relative lateral movement whereby thecolor is further spread.

6. In the manufacture of surface coverings, the steps consisting incoating a backing, applying color in spots to the coating while thelatter is still plastic, spreading the color into sinuous streaks, andthen further spreading the streaked color by a doctor blade.

7. In the manufacture of surface coverings, the steps consisting incoating a backing, applying color to the coating while the latter isstill plastic, spreading the color into sinuous streaks by means of areciprocating doctor blade, and then further spreading the streakedcolor.

8. In the manufacture of surface coverings, the steps consisting incoating a backing, applying color to the coating while the latter isstill plas- 1' tie, passing the same under a doctor blade and effectingrelative lateral movement of the doctor blade and the material so as tospread the color into sinuous streaks, passing the same under a seconddoctor blade and effecting relative lateral movement so as to furtherspread the color, and varying the angularity of at least one doctorblade relative to the path of movement of the material.

9. In the manufacture of surface coverings, the steps consisting incoating a backing, applying color to the coating while the latter isstill plastic, passing the same under a doctor blade and effectingrelative lateral movement of the doctor blade and the material so as tospread the color into sinuous streaks, passing the same under a seconddoctor blade and effecting relative lateral movement so as tofurtherspread the color, and varying the amplitude of said relativelateral movement for at least one of the doctor blades.

10. In the manufacture of surface coverings,

i the steps consisting in coating a backing, applying color to thecoatingwhile'the latter-is still plastic, passing the same under adoctorbl'ade and"eifectingrelativc lateral movement of the doctor bladeand. the material so as to spread the color into sinuous streaks,passing the same under a second doctor blade and effecting relativelateral movement so as to further spread thecolor, said relativemovement of .the doctor blades and the material being in 'a reciprocablemanner, and varying the number ofreciprocations of at least one of thedoctor blades in a unit of time.

11. Apparatus :for the manufacture of patter'ned surface coveringscomprising a doctor blade adaptedto'engage material moving thereunder,means-for reciprocating the doctor blade, and means for varying thedirection of movement of the doctor blade relative to the direction ofmovement of the material.

' 12. Apparatus for the manufacture of. patterned surface coveringscomprising means for advancing material, a doctor blade lying over themoving material, means for causing relative lateral movement between thedoctor blade and' the material, and means for varying the speed of suchmovement.

13. Apparatus for the manufacture of patterned surface coveringscomprising means for advancing material, a doctor blade lying over themoving material, means for causing relative lateral movement between thedoctor blade and the material, and means for varying the angularity ofthe doctor blade relative to the direction of movement of the material.

14. Apparatus for the manufacture of patterned surface coveringscomprising means for advancing material, a doctor blade lying over themoving material, and means for causing relative lateral movement betweenthe doctor blade and the material, said means being effective forcausing lateral movement in varying amounts.

15. Apparatus for the manufacture of surface coverings comprising meansfor moving the surface covering material, and a plurality ofreciprocable doctor blades engaging said material.

16. Apparatus for the manufacture of surface coverings comprising meansfor moving the surface covering material, and a plurality ofreciprocable doctor blades engaging said material, said blades beingindividually adjustable as to direction relative to the path of movementof the material.

17. Apparatus for the manufacture of surface coverings comprising meansfor moving the surface covering material, and a plurality ofreciprocable doctor blades engaging said material, said blades beingindividually driven for reciprocation.

18. Apparatus for the manufacture of surface coverings comprising meansfor applying spots of color to the material, and a plurality of doctorblades for successively engaging the same, at least one of the doctorblades being reciprocable.

19. Apparatus for the manufacture of surface coverings comprising meansfor advancing a backing, means for applying wet color composition to thebacking, means for applying wet color composition to the previouslyapplied composition, a doctor blade for engaging the same as the backingis advanced, and means for reciprocating the doctor blade.

20. Apparatus for the manufacture of surface coverings comprising meansfor advancing a backing, means for coating the backing, means forspraying color in spots onto the coating, a doctor blade for engagingthe, same as the backing is advanced, and means for reciprocating thedoctor blade.

21. In the manufacture or surface coverings, the steps consisting inapplying wet color to a backing, engaging the wet color with a doctorblade and eilecting relative lateral and longitudinal movement betweenthe backing and the doctor blade so as to spread the color and, whflethe spread color is still wet, again mechanically engaging the same andfurther spreading it.

22. In the manufacture of surface coverings, the steps consisting inapplying wet color to a backing, mechanically engaging the wet color soas to spread the same laterally and longitudinally and, while the spreadcolor is still wet,

engaging it with a doctor blade and effecting relative lateral andlongitudinal movement between the doctor blade and the backing so as tofurther spread the color.

diilerent portions oi the backing, engaging the wet'colorwith a doctorblade arranged at an angle to the longitudinal direction of the goods,moving the goods longitudinally under the doctor blade and laterallymoving the doctor blade so as to spread the wet color.

J. CLARENCE MCCARTHY.

